A Review Paper on Design & Development of Helical Gear by using ANSYS & AGMA Standards

A Review Paper on Design & Development of Helical Gear by using ANSYS & AGMA Standards

Mr. Sharad J. Chauhan1

Department of Mechanical Engineering ITM-Universe

Vadodara, India

Mr. Abhishek Dubey3

Department of Mechanical Engineering ITM-Universe

Vadodara, India

Mr. Parth K. Patel 2

Department of Mechanical Engineering ITM-Universe

Vadodara, India

Mr. Deepkumar K. Patel4 Department of Mechanical Engineering ITM-Universe

Vadodara, India

AbstractThis Review Paper gives the information about Bending and Contact Stress Analysis of Helical Gear. Thus, this review paper mainly focus on the ANSYS, finite element methods and AGMA standards for computation of bending and contact stress on a root of helical gear. In this paper the bending stress and contact stress of the gear tooth are examined and are to be one of the main contributors for the failure of the gear in a gear set. Thus, the analysis of stresses has become popular as an area of research on gears to minimize or to reduce the failures and for optimal design of gears.

Authors have use various Approaches and means to conclude their main objective of finding out the contact stresses and gear failure causes in static condition using Finite Element Analysis, AGMA Standards and ANSYS. This review paper contains theoretical, numerical and analytical methods for the helical gear pair analysis.

Keywords Helical gear; Ansys; AGMA Standards; Creo; FEA analysis; Bending strength; Helix angle; Pressure angle

1. INTRODUCTION

   Gears are most universal means of transmitting power in the modern mechanical engineering world. With the moving wheel of science and technology the use of gears has become more common in all the upcoming industries. Gearing is one of the most valuable methods for transmitting power and rotary motion. Helical gears are currently being used increasingly as a power transmitting gear owing to their relatively smooth and silent operation, large load carrying capacity and higher operating speed. Helical gears have smoother and silent operation than the spur gears because of a large helix angle that increase the length of the contact lines. Helical gears will have more capabilities to transmit load between two parallel shafts as compared to similar module and equivalent width of spur gears. Designing highly loaded helical gears for power transmission systems that are good in strength and low level in noise necessitate suitable analysis

   methods that can easily be put into practice and also give useful. Helical gears are used in fertilizer industries, printing industries and earth moving industries. Helical gears are also used in steel rolling mills, section rolling mills, power and port industries. Helical gears have more advantages than other gears especially spur gears like it has smoother engagement of teeth, silent in operation, can handle heavy loads and power can be transferred between non parallel shafts, high efficient etc. Due to these advantages it has wide range of applications in high speed high power mechanical systems.

   Fig. Helical gear

2. LITERATURE REVIEW

   Haider Shahad Wahad, Ajeet Kumar Rai and Prabhat Kumar Sinha[1] This work investigates the characteristics of an involute helical gear system mainly focused on bending stresses using ANSYS. To estimate the bending stress, modeling is generated by CATIA5 and numerical analysis is done by ANSYS. The analytical study is based on Lewis formula. Study is conducted by varying the face width to find its effect on the bending stress of helical gear. The face width is an important geometrical parameter in design of helical gear as it is expected in this work the maximum bending stress decreases with increasing face width. In this the stresses are found out by Lewis equations, AGMA results and ansys results . graph of this three results are compared. Effects of facewidth on the stresses are shown.

   Fig Static Structural Analysis of Helical Gear Having 32 Teeth (face width = 32mm)

   Dr. M. S. Murthy and Pushpendra Kumar Mishra[2] This paper presents a detailed study of different techniques proposed and used by various researchers to optimize and to calculate the stresses involved in the helical gear design. In this paper the analysis and modelling is done by using ansys and creo The stresses are checked at varying face width and helix angle. in this work a study is conducted on various works in which the effect of varying face width and helix angle on the bending stress of helical gear are studied. A critical study is also conducted on the tools or methods like FEM, TCA etc. that are utilized in carrying out studies on face width and helix angle to identify if the existing methods are the optimal methods or any suitable methods can be suggested to improve the existing methods or support them in making the methods more users friendly.

   BabitaVishwakarma, Upendra Kumar Joshi [3] This paper investigates finite element model for monitoring the stresses induced of tooth flank, tooth fillet during meshing of gears. The involute profile of helical gear has been modelled and the simulation is carried out for the bending and contact stresses and the same have been estimated. To estimate bending and contact stresses, 3D models are generated by modeling software CATIA V5 and simulation is done by finite element software package ANSYS 14.0. Analytical method of calculating gear bending stresses uses Lewis and AGMA bending equation. For contact stresses Hertz and AGMA contact equation are used. Study is conducted by varying the face width to find its effect on the bending stress of helical gear. It is therefore observed that the maximum bending stress decreases with increasing face width. The stresses found from ANSYS results are compared with those from theoretical and AGMA values.

   S. Jyothirmai, R. Ramesh, T. Swarnalatha, D. Renuka [4] presented a comparative study on helical gear design and its performance based on various performance metrics through finite element as well as analytical approaches. The theoretical analysis for a single helical gear system based on American Gear Manufacturing Association (AGMA) standards has been assessed in Matlab. The effect of major

   performance metrics of different helical gear tooth systems such as single, herringbone and crossed helical gear are studied through finite element approach (FEA) in ANSYS and compared with theoretical analysis of helical gear pair. Structural, contact and fatigue analysis are also performed in order to examine the performance metrics of different helical gear systems. The advantage of such a comparison is rapidly estimating the stress distribution for a new design variant without carrying out complex theoretical analysis as well as the FEA analysis gives less possibility for labour-intensive errors while scheming complex formulas related to theoretical analysis of gears. It will significantly reduce processing time as well as enhanced flexibility in the design performance. It was initiate that the overall performance of crossed helical gear was found to be the best in terms of stress as well as tooth strength at low loads whereas herringbone and single helical gear systems are employed for optimum values of speeds and loads.

   Raghava Krishna Sameer.B, V.Srikanth[5] In this paper research has been made on gears to minimize the vibrations, bending stresses and also reducing the mass percentage in gears. These stresses are used to find the optimum design in the gears which reduces the chances of failure. The model is generated by using CATIAV5 and ANSYS is used for numerical analysis. he analytical study is based on Hertzs equation. Study is conducted by varying the geometrical profile of the teeth and to find the change in contact stresses between gears. The contact stresses which are acting on the modified helical gears are more when compared to the standard helical so These paper pretends to be failure theory by which the design aspects are to no changed to reduce the contact stresses. The two different result obtained by the ansys with different geometries are compared. Based on the result from the contact stress analysis the hardness of the gear tooth profile can be improved to resist pitting failure.

   Tribhuwan Singh, Mohd. Parvez[6] This thesis is to investigates the characteristics of an involute helical gear system mainly focused on bending and contact stresses using analytical and finite element analysis. To estimate the bending stress using ProE that is a powerful and modern solid modeling software and the numerical solution is done by ANSYS, which is a finite element analysis package. The analytical investigation is based on Lewis stress formula. Present method of calculating gear contact stress uses Hertz's equation. Face width and helix angle are important geometrical parameters in determining the state of stresses during the design of gears. The theoretical calculations were made by lewis stress formula and for calculating contact stress by Hertzs equation and the result obtained by it is compared with the experimental results of ansys This paper is about says that maximum bending stress decreases with increasing face width and it will be higher on gear of lower face width with higher helix angle. As a result, based on this finding if the material strength value is criterion then a gear with any desired helix angle with relatively larger face width is preferred.

   1. Venkatesh & Mr. P. B. G. S. N. Murthy[7] The analysis of stresses has become popular as an area of research on gears to minimize or to reduce the failures and for optimal design of gears In this paper bending and contact stresses are calculated by using analytical method as well as Finite element analysis. To estimate bending stress modified Lewis beam strength method is used. Pro-e solid modeling software is used to generate the 3-D solid model of helical gear. Ansys software package is used to analyze the bending stress. Contact stresses are calculated by using modified AGMA contact stress method. In this also Pro-e solid modelling software is used to generate contact gear tooth model. Ansys software package is used to analyze the contact stress. Finally these two methods bending and contact stress results are compared with each other In this work analytical and Finite Element Analysis methods were used to predicting the Bending and contact stresses of involute helical gear. Bending stresses are calculated by using modified Lewis beam strength equation and Ansys software package. Contact stresses are calculated by using AGMA contact stress equation and Ansys software package.

3. CONCLUSION

   From this paper of design and development of helical gear by using ANSYS and AGMA standards we can conclude that, This paper presented a brief review of design and modelling and analysis of high speed helical gear using AGMA and ANSYS with various face width and helix angle and found their effect due to bending and contact stress and its value compared with ANSYS and AGMA. The contact stresses are inversely proportional to the helix angle and helix angle is important parameter in computation of the state of the stress during the design of gear.

4. ACKNOWLEDGEMENT

   This review paper is partially supported by ITM- UNIVERSE. We thank our colleagues from ITM- UNIVERSE who provided insight and expertise that greatly assisted the research, although they may not agree with all the interpretation of this paper.

   The completion of the review paper would not have taken place without the contribution of key person. The progress of the review paper for the project was supervised by Asst. Prof. Jay Mandalia from Mechanical Department of Institute of Technology and Management Universe for assistance with his useful knowledge and expertise for his comments that greatly improve the manuscript. A special thanks to our Head of the Department Prof. Minesh Patel. Their guidance, advice and wisdom throughout this work are also greatly appreciated.

   Finally special thanks to my family and colleagues who provided constant support and encouragement during this work.

5. REFERENCES

1. Modeling and Analysis of involute helical gear using CATIA and ANSYS softwares by Haider Shahad Wahad*, Ajeet Kumar Rai and Prabhat Kumar Sinha published in International Journal of Mechanical Engineering and Technology (IJMET),Volume 4, Issue 5, September – October (2013), pp. 182-190.

2. Stress Analysis Of Helical Gear By FEM Techniques With Variation In Face Width And Helix Angle by Dr. M. S. Murthy and Pushpendra Kumar Mishra published in International Journal of Engineering Research & Technology (IJERT) Vol. 2 Issue 7, July 2013 ISSN: 2278-0181.

3. Finite Element Analysis of Helical Gear Using Three- Dimensional Cad Model by BabitaVishwakarma, Upendra Kumar Joshi in International Journal of Engineering Sciences & Research Technology (2014).

4. A Finite Element Approach to Bending, Contact and Fatigue Stress Distribution in Helical Gear Systems, by S. Jyothirmai, R. Ramesh, T. Swarnalatha, D. Renuka in 3rd International Conference on Materials Processing and Characterisation, pp.907- 918, (ICMPC 2014).

5. contact stress analysis of modified helical gear using CATIA and ANSYS by raghava krishna sameer.b, v.srikanth published in international journal of computer science information and engg., technologies issn 2277-4408.

6. Comparative study of stress analysis of helical gear using AGMA standards and FEM by Tribhuvan Singh, Mohd. Parvez in international journal of engineering science and research technology, July, 2013 ISSN: 2277-9655

7. Design and Structural Analysis of High Speed Helical Gear Using ANSYS, by J. Venkatesh, Mr. P. B. G. S. N. Murthy in International Journal of Engineering Research and Applications, Vol. 4, Issue 3 (Version 2), pp.01-05,(2014).